INCREASING EFFICIENCY THROUGH INNOVATIONS ON ROTOMOULDING MACHINES. Walter Bonazzi Polivinil Rotomachinery S.P.A.

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1 INCREASING EFFICIENCY THROUGH INNOVATIONS ON ROTOMOULDING MACHINES Walter Bonazzi Polivinil Rotomachinery S.P.A.

2 We, ROTOMACHINERY GROUP, believe that in a general market situation where: -PRIVATE DEMAND IS WEAK ( REDUCTION OF INCOME) -PUBLIC INVESTMENTS ARE LOW ( GOVERNMENT BUDGET POLICIES) - COSTS ARE INCREASING ( FIXED COSTS FOR A REDUCED OUTPUT) - PROFIT ARE DECREASING ( NO POSSIBILITY TO TRANSFER INCREASED COSTS ON THE SELLING PRICES) Rotomoulders can keep their business profitable and maybe improve market shares investing in efficiency of the production.

3 HOW TO INCREASE EFFICIENCY? Reduction of the operational cost for a given output level Increasing the output at the same cost level THE GOAL IS ACHIEVED THROUGH: - GOOD PRODUCTION ORGANIZATION AND - GOOD MACHINERY AND MOULDS

4 Perfect lay-out of the site and skilled people working with an inefficient machine OR TOP CLASS machinery operating in bad production situation ARE THE CAUSES OF INEFFICIENCY Our committment to the market is to provide high-tech machinery with: - Safe - Efficient; - Reliable; - User friendly.

5 At the inauguration of the new research centre in Italy on last 23rd November POLIVINIL ROTOMACHINERY presented the new generation machine (PRM3200-3C). This machine has been designed having efficiency in mind. AND THE RESULTS ARE THE FOLLOWING INNOVATIONS: 1 Regeneration unit; 2 ECO MODE; 3 Heating fan with two turbines; 4 Totally digital controlled burner; 5 Consumption monitoring; 6 New upper conduct fan; 7 Datas protection; 8 New cooling fan system.

6 REGENERATION UNIT Every time an electric motor reduces the speed or reverses the rotation there's a production of regenerative energy. On a rotational moulding machine this happen quite often: - Deceleration of the oven doors; - Deceleration of the carts in positioning - Deceleration / reserve of primary / secondary rotation; - Deceleration of the oven and cooling fans. Every time an electric motor reduces the speed or reverses the rotation there's a production of regenerative energy. WHY TO WASTE THIS ENERGY? WE HAVE INSTALLED 'REGEN' TO USE IT.

7 WHAT IS REGEN? REGEN is a special bi-directional power supply serving all the machine motors now controlled by inverters. Inverters convert DC in AC corrent and return the energy generated from the motors during the phase of deceleration or stop, when the motors act as generator. REGEN takes with energy return and use it for the other motors and when this energy exceed the machine needs, it will put it in the general circuit to feed other utilities (light of the building, for example). At any time you can see on the display, the quantity of the energy re-used and the quantity of the energy input in the general circuit.

8 ECO MODE ECO MODE is a working modality of the oven, designed to reduce energy consumption. The basic principle is that the burner stops when the oven is empty or the temperature falls below the set (ex 200 ). The machine enters in ECO MODE by simply tapping the icon on the touchscreen.

9 WHEN ECO MODE ADVANTAGES ARE MAXIMIZED: Full digitally controlled burner; Real-time display of all the data of the combustion to compare with the optimum and find the more efficient mix. Heating fan with two turbines, each turbine is controlled with an inverter with reduced time of stop and restart. Automatic recycle of the cycle cooking and cooling times are given by the real time temperature data achieved by the termocouples inside the mould. Well insulated oven panel to reduce at minimum heat dispersion

10 HOW IT WORKS: LET'S SEE ECO MODE IMPACT ON THE CYCLE END OF THE COOKING CYCLE In ECO MODE the turbines stop when the oven doors open to reduce the energy loss from the doors. This take 5 seconds not 1 minute as in the case of one big fan. ADVANTAGES: - Huge reduction of hot air release; - Big regenerative energy creation; - Only C of loss of temperature.

11 BURNER SWITCHED OFF In eco mode the burner is switched off when the oven is empty. The restart of the burner increases the time needed to restore the temperature set and the automatic management software increases cooking time accordingly. The advantages are consistent for a well-insulated oven: - Savings in energy consumption (for the time when the burner is off) are more compared to disadvantages (of the increased cooking time); - Big savings are achieved in case of unbalanced cycle time when the oven is empty for long time; - With ECO MODE the first cycle in the morning could be run without pre-heating; - On the last cycle the burners turns off automatically.

12 ACTIVE MANAGEMENT OF THE EXHAUST FAN The exhaust fan ejects the hot air with the combustion fumes and replenish with the clean air. This means a continuos loss of energy. With ECO MODE when the burner is off the exhaust fan works at the minimum speed. If the increased cooking time is not acceptable, for any reason, ECO MODE can be turned off, keeping all the advantages of the regenerative unit.

13 UPPER FAN DUCT In the hot air circulation system inside ROTOMACHINERY GROUP ovens the hot air after the heating of the mould returns to the burner to be reheated. We have used 6 thermocouples to optimize the design of the oven and have seen real-time that the difference in temperature before and after the mould is not so much. Our engineers have studied a supplementary hot air duct that reuses the hot air working as a supplementary mould heating point. This way the mould is heated from two sides with reduction of cooking time which is automatically reduced according to the data sent to the software by the thermocouples inside the mould.

14 CONSUMPTION MONITORING First step to any improvement and decision to take is knowing which is the real consumption. ROTOMACHINERYGROUP's new generation machines have on board a gas meter showing every 10 seconds the instant consumption and electricity consumption in kw. THE DATAS CAN BE ORGANIZED FOR: - Working conditions (empty oven/cooking phase); - Single moulding cycle; - Per arm; - Per cubic meter, Weight of the parts; - Different period: hour/day/shift/month. The datas can be displayed on remote devices: PC, phone and tablet.

15 KEEPING THE DATA SAFE Once the supervisor have entered the working parameters (full automatic, partial automatic, manual, ECO MODE) and the production data (recipes, times and temperature) to avoid operator's misuses or changes in parameters the settings are protected with a password-level system. The problem of password loss or password revelation is solved with the fingerprint authentication where only the supervisor can change the main parameters. Fingerprint maps are protected and cannot be downloaded, protecting the privacy.

16 NEW COOLING FANS We have tested and finally installed new type of blowing fans. THE ISSUES WITH THE OLD COOLING FANS WERE: - Noise level: 80 dba - Energy absorptions: 3KW each mc/h NEW FANS IMPROVED: - Noise level: 75 dba - Energy absorptions: 1 KW each mc/h

17 MANUFACTURER'S WEB SITES, PRESS RELEASES, MEETINGS AND DIRECT CONTACTS ARE THE BEST WAY TO KNOW WHAT'S GOING ON IN INNOVATION ON PROCESS AND MATERIAL CONTACT US TO KNOW MORE REGARDING THE IMPROVEMENTS ON THE TESTS DONE BY THE ROTOMACHINERY GROUP AND FEEL WELCOME TO COME AND MEET US!